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[Transmission] clutch cable confusion! 1.6 hdi
#1
   
       
[attachment=2471]
[attachment=2470]
Berlingo 1.6 Hdi GH9HXC ENGINE WITH 90 HP

Hello everyone,

I've had a growing problem with my clutch for the last few years; a cracking sound at the pedal end of the clutch which has deteriorated to the point wherethe clutch can't be operated (the pedal doesn't engage the clutch anymore,) I suspected the cable or the plastic pin at the end, as in betrween this problem the clutch worked fine.
Sooo..I've removed the old cable and pivot pin and got replacements based on the engine/gearbox number.
The new pin is indentical to the one I removed, but the cable isn't. The new one has the obvious auto cable adjuster but the old one..i don't know..it looks radically different. All of the cables I've searched for resemble the new one and not the old in in design. I don't want to fit the wrong one..I bought the car second hand..maybe the original cable is wrong? I've attached pics of the cables in question:
Any help would be welcome!
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#2
Where did you get the cable from?  Some factors are a bit clueless.Have you tried GSF? They're usually pretty good.My 1.6HDi has a hydraulic clutch.Good luck & come back if you need more help. Big Grin Ps.I've just noticed you are in Germany Is it a left hooker?If so there is a German Berlingo forum who may be able to point you in the right direction.
Strawberry flavoured windows  Dodgy
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#3
   
(03-09-2015, 09:32 PM)ron Wrote:  Where did you get the cable from?  Some factors are a bit clueless.Have you tried GSF? They're usually pretty good.My 1.6HDi has a hydraulic clutch.Good luck & come back if you need more help. Big Grin Ps.I've just noticed you are in Germany Is it a left hooker?If so there is a German Berlingo forum who may be able to point you in the right direction.

Hi Ron,
thanks for your reply Smile
It is a lefty! It's an ATE part and was the only one on ebay germany that corresponded most closely to the engine details i entered.
I've looked online and the old cable mostly resembles earlier cables used on earlier1.8i petrol models..so i'm wondering if somebody swapped the wrong cable in at some point (I've only had the car for 2 years of it's 9 year life.
I've attached a photo of the packaging label. To me, it looks like it should be ok..it just doesn't resemble the one in there! I think your hydraulic clutch is the more modern one.
I did put the car's details into other parts stockists and they all popped up with similar designs (with the auto adjust protected by a white cover) as the one i ordered. Maybe I should just try to fit it and see what happens..
It's due to rain all weekend in hamburg so tomorrow's my window of opportunity..i'll let you know what happens!
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#4
Hi Cober.Thats certainly an awkward one,and i can understand your frustration and concern.I am surprised that your having problems with such a heavy duty cable on an 06 car.Has the car got loads of miles or a particularly stiff clutch ? Obviously the cable would be different than on a R/H drive car and i think shorter.Have you a paper history with the car which you could look through for clues,or would you be able to contact the previous owner for any history information?
Clutch cables are pretty simple things anyway so i think if it was me i'd bite the bullet,suck it in and have a go,you should be able to tell within a fairly short time if itll go in ,my advice would be to go careful so if there's no way it'll go in at least youll be able to take it back for a refund.Good luck and do tell us the outcome.
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#5
Hi Guys

well I'm sure I will be posting that everything failed in the recent future but for the moment i feel like the cat that got the cream, ate the cream, checked his ticket and won the lottery! I just got back from my Berlingo having driven it at least 500 yards, changing gear and all, without crunching or grinding noises!

It's early days but all seems well.

I also cleared up a few puzzling issues while I was changing the cable; One reason the old one i photographed looked different was that it was missing part of the rubber shroud that goes on the pedal end..I found it wedged in the engine compartment as I was trying to fit the new one..I reckon it ripped off as I was pulling the old cable through.
After removing the while plastic retainer from the new cable, underneath was a rubber concertina-formed shroud which resembles the old cable.
I couldn't thread the cable through where it should go without removing the battery tray and fittings and then the securing mount attached to the end of the gearbox. (I didn't know that's what it was until the gearbox and engine, to my horror, dropped a good few inches toward the ground.) At that point I thought I'd knackered up the whole car. I threaded the cable through (much more room now Smile and then jacked the gearbox up until i could get a bolt on it again.
I put the rest back together and at the second attempt (after removing the white plastic retainer) everything seems to work!
I still have some concerns..the clutch pedal travel was  always pretty short ( the pedal sits quite a bit below the brake and gas pedals) and the new cable hasn't made any difference to this - but it changes gear without any grind, at least at the moment.
I also struggled to find fixings for the new cable- just one in fact that I was able to access...

but at the moment I am a happy bunny! I will let you know if anything changes and thank you guys for you interest and help!
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#6
(04-09-2015, 03:07 PM)cober Wrote:  Hi Guys

well I'm sure I will be posting that everything failed in the recent future but for the moment i feel like the cat that got the cream, ate the cream, checked his ticket and won the lottery! I just got back from my Berlingo having driven it at least 500 yards, changing gear and all, without crunching or grinding noises!

It's early days but all seems well.

I also cleared up a few puzzling issues while I was changing the cable; One reason the old one i photographed looked different was that it was missing part of the rubber shroud that goes on the pedal end..I found it wedged in the engine compartment as I was trying to fit the new one..I reckon it ripped off as I was pulling the old cable through.
After removing the while plastic retainer from the new cable, underneath was a rubber concertina-formed shroud which resembles the old cable.
I couldn't thread the cable through where it should go without removing the battery tray and fittings and then the securing mount attached to the end of the gearbox. (I didn't know that's what it was until the gearbox and engine, to my horror, dropped a good few inches toward the ground.) At that point I thought I'd knackered up the whole car. I threaded the cable through (much more room now Smile and then jacked the gearbox up until i could get a bolt on it again.
I put the rest back together and at the second attempt (after removing the white plastic retainer) everything seems to work!
I still have some concerns..the clutch pedal travel was  always pretty short ( the pedal sits quite a bit below the brake and gas pedals) and the new cable hasn't made any difference to this - but it changes gear without any grind, at least at the moment.
I also struggled to find fixings for the new cable- just one in fact that I was able to access...

but at the moment I am a happy bunny! I will let you know if anything changes and thank you guys for you interest and help!

Phew Cool thats great news.Im really pleased for you,doesnt it make you feel good when a plan comes together.More power to your elbow cober.
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#7
(04-09-2015, 03:07 PM)cober Wrote:  Hi Guys

well I'm sure I will be posting that everything failed in the recent future but for the moment i feel like the cat that got the cream, ate the cream, checked his ticket and won the lottery! I just got back from my Berlingo having driven it at least 500 yards, changing gear and all, without crunching or grinding noises!

It's early days but all seems well.

I also cleared up a few puzzling issues while I was changing the cable; One reason the old one i photographed looked different was that it was missing part of the rubber shroud that goes on the pedal end..I found it wedged in the engine compartment as I was trying to fit the new one..I reckon it ripped off as I was pulling the old cable through.
After removing the while plastic retainer from the new cable, underneath was a rubber concertina-formed shroud which resembles the old cable.
I couldn't thread the cable through where it should go without removing the battery tray and fittings and then the securing mount attached to the end of the gearbox. (I didn't know that's what it was until the gearbox and engine, to my horror, dropped a good few inches toward the ground.) At that point I thought I'd knackered up the whole car. I threaded the cable through (much more room now Smile and then jacked the gearbox up until i could get a bolt on it again.
I put the rest back together and at the second attempt (after removing the white plastic retainer) everything seems to work!
I still have some concerns..the clutch pedal travel was  always pretty short ( the pedal sits quite a bit below the brake and gas pedals) and the new cable hasn't made any difference to this - but it changes gear without any grind, at least at the moment.
I also struggled to find fixings for the new cable- just one in fact that I was able to access...

but at the moment I am a happy bunny! I will let you know if anything changes and thank you guys for you interest and help!

Well done.You deserve an evening out in St Pauli Big Grin Big Grin
Strawberry flavoured windows  Dodgy
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#8
Hi to you,

so just a quick follow-up; all is fine, now. I played around with the clutch foot pedal positioning and rotated it as foward as it would go. It seems to have much more travel now and the gears are a joy to change. i have to adjust my driving position as I got used to the pedal sitting so low, but there's less vibration thriu the pedal and all is much smoother; like other 'normal cars'.

so once again thanks for all your help and support!

Cober
Reply
#9
(06-09-2015, 03:55 PM)cober Wrote:  Hi to you,

so just a quick follow-up; all is fine, now. I played around with the clutch foot pedal positioning and rotated it as foward as it would go. It seems to have much more travel now and the gears are a joy to change. i have to adjust my driving position as I got used to the pedal sitting so low, but there's less vibration thriu the pedal and all is much smoother; like other 'normal cars'.

so once again thanks for all your help and support!

Cober

More power to your elbow !
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